Composite article joined with an adhesive

ABSTRACT

A method of joining textile elements and an article formed by joined elements is disclosed. The method includes bonding together textile elements through the use of an adhesive element and the application of heat and pressure. The method also includes joining the bonded textile elements to another textile element to create an aesthetic functional article.

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application is a continuation-in-part of and claims benefitto U.S. application Ser. No. 10/382,798 filed Mar. 5, 2003.

BACKGROUND OF THE INVENTION

[0002] 1. Field of the Invention

[0003] The present invention relates to a method for joining textileelements. The invention concerns, more particularly, a method ofutilizing a polymer adhesive to join textile elements in applicationssuch as apparel.

[0004] 2. Description of Background Art

[0005] Textiles may be defined as any manufacture from fibers,filaments, or yams characterized by flexibility, fineness, and a highratio of length to thickness. Textiles generally fall into twocategories. The first category includes textiles produced directly fromwebs of fibers by bonding, fusing, or interlocking to constructnon-woven fabrics and felts. The second category includes textilesformed through a mechanical manipulation of yam, thereby producing awoven fabric.

[0006] Yarn is the raw material utilized to form textiles in the secondcategory. In general, yarn is defined as an assembly having asubstantial length and relatively small cross-section that is formed ofat least one filament or a plurality of fibers. Fibers have a relativelyshort length and require spinning or twisting processes to produce a yamof suitable length for use in textiles. Common examples of fibersinclude cotton and wool. Filaments, however, have an indefinite lengthand may merely be combined with other filaments to produce a yamsuitable for use in textiles. Modem filaments include a plurality ofsynthetic materials such as rayon, nylon, polyester, and polyacrylic,with silk being the primary, naturally-occurring exception. Yarn may beformed of a single filament (conventionally referred to as amonofilament yarn) or a plurality of individual filaments. Yarn may alsobe formed of separate filaments formed of different materials, or theyarn may be formed of filaments that are each formed of two or moredifferent materials. Similar concepts also apply to yarns formed fromfibers. Accordingly, yarns may have a variety of configurations thatgenerally conform to the definition provided above.

[0007] Separate textile elements, whether classified within the first orsecond category, are often joined to produce a variety of consumerarticles, including apparel, for example. Conventionally, the textileelements are joined through stitching, which is the interweaving of ayarn through two or more textile elements to secure the textile elementstogether. Although stitching may be accomplished by hand, which isrecognized as a labor-intensive and inefficient process, sewing machinesare generally utilized to stitch the textile elements together, therebyforming a seam between the textile elements.

[0008] Stitching is the most prevalent method of joining textileelements in modern industry. The process of stitching and the resultingstitched area, however, are subject to certain limitations. For example,sewing machines are generally configured to form a linear or graduallycurving seam, rather than highly-curved or angular seams, therebylimiting the configuration of the resulting product. In addition, theedges of the textile elements may unravel if not properly surged,hemmed, or turned during the stitching process, which adds technicaldifficulty to the stitching process and may result in defective articlesif not properly executed. Furthermore, many seams may include three ormore layers of textile, due to hemming or turning of the textileelements, which increase the thickness of the seam and may representareas of discomfort in the article.

[0009] As an alternative to stitching the edges of textile elementstogether, Bemis Associates, Inc. of Shirley, Mass., United Statesmanufactures polymer heat seal seam tapes that may be utilized toreinforce seams, replace stitching, bond labels and embroidery togarments, and prevent fraying, for example. The seam tapes arethermoplastic polymers that may be applied by commercially-availabletaping machines and join textile elements formed of a variety ofmaterials, including polyester, cotton, and blended fabrics that includeboth polyester and cotton fibers, for example.

SUMMARY OF THE INVENTION

[0010] The invention is a method of joining a first textile element anda second textile element. As an initial step in the method, the firsttextile element, the second textile element, and an adhesive element areprovided. A first bond is then formed between the first textile elementand the adhesive element to define a bonded area and an unbonded area.An aperture is then defined in the first textile element and theadhesive element by removing at least a portion of the bonded area.Finally, a second bond is formed between the second textile element andthe bonded area, thereby joining the first textile element and thesecond textile element.

[0011] The first textile element is generally larger than the secondtextile element and the adhesive element. In one configuration, thesecond textile element and the adhesive element are formed to havesubstantially similar dimensions. The relative sizes of the variouselements leads to a structure wherein the adhesive element and secondtextile element are located in a spaced relationship with edges of thefirst textile element. Accordingly, the position of the second textileelement is generally within an interior portion of the first textileelement, rather than on an edge of the first textile element. In otherconfigurations, however, the second textile element and the adhesiveelement may have different dimensions, and the second adhesive elementmay be located on an edge of the first textile element. In yet otherconfigurations, a third textile element may be formed to have similardimensions as the adhesive element and both joined to the second textileelement that, in turn, may be joined or bonded to the first textileelement.

[0012] The primary purpose of the adhesive element is to form a bondwith the textile elements, thereby joining the textile elements. In anexemplary embodiment, by configuring the second textile element and theadhesive element to have similar dimensions, and by defining theaperture within the bonded area, the adhesive element is shaped andsized to contact at least the perimeter of the second textile element toform the second bond.

[0013] The bonds between the adhesive element and the textile elementsare generally formed through heat and pressure, but may also be formedthrough radio frequency or ultrasonic bonding processes. The amount ofheat and pressure applied to form the bonds depends upon the specificmaterial utilized for the adhesive element, which may be a thermoplasticpolymer, such as polyurethane, polyamide, polyester, polyolefin, orother suitable material. In general, the heat and pressure induces theadhesive element to infiltrate the structure of the textile elements.Upon subsequent cooling, the adhesive element becomes securely bonded tothe textile elements.

[0014] The advantages and features of novelty characterizing the presentinvention are pointed out with particularity in the appended claims. Togain an improved understanding of the advantages and features ofnovelty, however, reference may be made to the following descriptivematter and accompanying drawings that describe and illustrate variousembodiments and concepts related to the invention.

DESCRIPTION OF THE DRAWINGS

[0015] The foregoing Summary of the Invention, as well as the followingDetailed Description of the Invention, will be better understood whenread in conjunction with the accompanying drawings.

[0016]FIG. 1 is a plan view depicting a first surface of an articleformed in accordance with a method of the present invention.

[0017]FIG. 2 is a plan view depicting a second surface of the article.

[0018]FIG. 3 is a cross-sectional view, as defined by lines 3-3 in FIGS.1 and 2.

[0019]FIG. 4 is an exploded perspective view of the article.

[0020]FIG. 5 is a plan view of an article of apparel formed inaccordance with the method.

[0021]FIG. 6 is a plan view of a first textile element, a second textileelement, and an adhesive element in accordance with a first step in themethod.

[0022]FIG. 7 is a side elevational view of the first textile element,adhesive element, and a bonding apparatus prior to a second step in themethod.

[0023]FIG. 8 is a plan view of the adhesive element bonded to the firsttextile element in accordance with the second step in the method.

[0024]FIG. 9 is a plan view of the first textile element and theadhesive element in accordance with a third step in the method.

[0025]FIG. 10 is a side elevational view of the first textile element,second textile element, adhesive element, and a bonding apparatus priorto a fourth step in the method.

[0026]FIG. 11 is a plan view of another article formed in accordancewith the method of the present invention.

[0027]FIG. 12 is a plan view of yet another article formed in accordancewith the method of the present invention.

[0028]FIG. 13 is an exploded view of another article formed inaccordance with the method of the present invention.

[0029]FIG. 14 is an isometric view of the article of FIG. 13 formed inaccordance with the method of the present invention.

[0030]FIG. 15 is an isometric view of the article of FIG. 13 formed withanother article in accordance with the method of the present invention.

DETAILED DESCRIPTION OF THE INVENTION Introduction

[0031] The following discussion and accompanying figures disclose amethod of joining a first textile element and a second textile elementin accordance with the present invention.

[0032] The method may be incorporated into the manufacturing of aplurality of products to provide joined textile elements. Prior todiscussing the method, however, the structure of an article 10 andanother article 10 a, which are both formed in accordance with themethod, is disclosed to provide a greater understanding of the variouselements and the configuration of the elements that are utilized in themethod. Following the discussion of the method with respect to article10, a pair of articles 10 b and 10 c are disclosed to demonstratevariations upon the specific method utilized to for article 10.

[0033] Article 10 is depicted in FIGS. 1-4 as a generally layeredstructure that includes a first textile element 20, a second textileelement 30, and an adhesive element 40. First textile element 20includes an outer edge 21, an inner edge 22, and an aperture 23. Outeredge 21 defines a periphery of first textile element 20 and is depictedin FIGS. 1-4 with a rectangular shape. A component having the generalstructure of article 10 may be incorporated into a plurality ofproducts. Accordingly, the specific shape of first element 20, and outeredge 21 in particular, may vary significantly depending upon theparticular application intended for article 10. Inner edge 22 definesaperture 23 and is positioned in a spaced relationship with outer edge21, thereby locating aperture 23 in an interior portion of first textileelement 20. Inner edge 22 and aperture 23 are depicted in FIGS. 1-4 ashaving an ovate shape. As with outer edge 21, however, the shape ofinner edge 22 and aperture 23 may vary significantly depending upon theparticular application intended for article 10.

[0034] Second textile element 30 includes an outer edge 31 that definesa periphery of second textile element 30. The configuration of secondtextile element 30, and outer edge 31 in particular, is proportional toaperture 23, but the dimensions of second textile element 30 are greaterthan the dimensions of aperture 23. Accordingly, the shape of secondtextile element 30 is similar to the shape of aperture 23, but largerthan aperture 23. Second textile element 30 extends over adhesiveelement 40 and aperture 23, thereby covering aperture 23 and forming adifferent area of article 10 that is adjacent to aperture 23.

[0035] Adhesive element 40 is positioned between elements 20 and 30 andforms a bond with each of elements 20 and 30 to effectively joinelements 20 and 30. Adhesive element 40 includes an outer edge 41, anaperture edge 42, and an aperture 43. Outer edge 41 coincides with outeredge 31 of second textile element 30, and aperture edge 42 coincideswith aperture edge 22 of first textile element 20. Accordingly, adhesiveelement 40 is positioned at the interface of elements 20 and 30, andadhesive element 40 is positioned entirely between elements 20 and 30.Furthermore, aperture 43 coincides with aperture 23, as depicted in FIG.3, to form an opening that extends through both first textile element 20and adhesive element 40.

[0036] As will become apparent in the discussion of the method, outeredge 31 and outer edge 41 may be formed simultaneously or separatelythrough a die cutting operation, for example, so as to provide anequally proportioned and equally dimensioned shape to both secondtextile element 30 and adhesive element 40. Similarly, aperture edge 22and aperture edge 42 may be formed simultaneously to form apertures 23and 43 with equal proportions and dimensions.

[0037] First textile element 20 and second textile element 30 may be anymanufacture from fibers, filaments, or yarns, whether natural orsynthetic. Suitable textile materials for first textile element 20 andsecond textile element 30 are polyester, cotton, or blended fabrics thatinclude both polyester and cotton fibers, for example. One purpose ofthe present method is to join textiles with different properties.Accordingly, first textile element 20 and second textile element 30 maybe formed from different fibers. Alternately, first textile element 20and second textile element 30 may display different thicknesses ordegrees of abrasion resistance, different degrees of air-permeability,or different colors, for example.

[0038] Adhesive element 40 may be a thermoplastic polymer that formsbonds with first textile element 20 and second textile element 30through the application of sufficient heat and pressure, thereby joiningelements 20 and 30. Alternately, adhesive element 40 may be a materialthat forms the bonds through radio frequency or ultrasonic bondingprocesses, for example. With regard to the thermoplastic polymer, theamount of heat and pressure applied to form the bonds depends upon thespecific material forming adhesive element 40, which may bepolyurethane, polyamide, polyester, polyolefin, or vinyl. Suitablethermoplastic polymers formed from these materials may be supplied byBemis Associates, Inc. of Shirley, Massachusetts, United States. Ingeneral, the heat and pressure induces adhesive element 40 to soften ormelt so as to infiltrate the structure of the textile elements. Uponsubsequent cooling, adhesive element 40 becomes securely bonded to eachof first textile element 20 and second textile element 30.

[0039] Article 10 has advantages over articles formed throughconventional sewing techniques. As discussed above in the Background ofthe Invention, sewing machines are generally configured to form a linearor gradually curving seam, rather than highly-curved or angular seams,thereby limiting the configuration of the resulting product. Article 10includes second textile element 30 that has an irregular, non-linearshape that is effectively joined with first textile element 20. As willbecome apparent in the following discussion, second textile element 30may have any practical shape, whether the shape includes angles,small-radius curves, or other complex features.

[0040] With regard to the use of a conventional sewing machine, theedges of the textile elements may unravel if not properly surged,hemmed, or turned during the stitching process, which adds technicaldifficulty to the stitching process and may result in defective articlesif not properly executed. Aperture edge 22 and outer edge 31, whichgenerally form the edges located at the interface between first textileelement 20 and second textile element 30 are not surged, hemmed, orturned to prevent unraveling or fraying. Instead, adhesive element 40infiltrates the structures of first textile element 20 and secondtextile element 30 adjacent to edges 22 and 31, respectively, and bindsthe relative positions of the various fibers, filaments, or yarns.Accordingly, adhesive element 40 serves the dual purpose of preventingunraveling and fraying and forming bonds with first textile element 20and second textile element 30.

[0041] Seams formed through conventional sewing techniques often includethree or more layers of textile, due to hemming or turning of thetextile elements, which increases the thickness of the seams and mayrepresent areas of discomfort in the article. In contrast, article 10has a thickness of two textile layers, first textile layer 20 and secondtextile layer 30, which provides a relatively thin seam. Depending uponthe degree of heat and pressure applied in forming the bonds withadhesive element 40, however, adhesive layer 40 may add a negligibleincrease in the thickness of the interface between first textile element20 and second textile element 30.

[0042] An article 10 a is depicted in FIG. 5 in order to provide anexample of an application for textiles joined through the method of thepresent invention. Article 10 a is an article of apparel, particularly ashirt, that includes a trunk section 11 a and two sleeves 12 a and 13 a.Trunk section 11 a incorporates a component that is analogous to article10, as described above. Accordingly, trunk section 11 a includes a firsttextile element 20 a, a second textile element 30 a, and an adhesiveelement 40 a. First textile element 20 a and adhesive element 40 a forma plurality of apertures, and second textile element 30 a is positionedbehind the apertures and joined with first textile element 20 a on aninterior surface of trunk section 11 a. The combination of secondtextile element 30 a and the apertures in first textile element 20 a andadhesive element 40 a form a design in article 10 a, but may also beutilized to define numbers. Accordingly, a single aperture with a shapecorresponding with the shape of a number may be defined in first textileelement 20 a and adhesive element 40 a.

[0043] Article 10 a may be utilized, for example, as a ventilatedarticle of apparel, thereby cooling the individual. First textileelement 20 a may be formed of a material that wicks moisture away fromthe skin, thereby limiting the amount of moisture on the interior ofarticle 10 a. Second textile element 30 a may be formed of a material,such as a mesh material, that provides a relatively high degree ofair-permeability. During exercise, therefore, air may enter and exit thearea between article 10 a and the individual by passing through secondtextile element 30 a.

[0044] Many conventional articles of apparel incorporate mesh materialsto provide venting. In contrast with article 10 a, the mesh material ofconventional apparel is often positioned between other elements of theapparel and is joined with conventional sewn seams.

[0045] Second textile element 30 a, however, is positioned withininterior portions of first textile element 20 a and has an irregular,non-linear shape that would be difficult to efficiently reproduce withconventional sewing techniques. Furthermore, second textile element 30 aforms a functional graphic, which operates to simultaneously ventilatearticle 10 a and provide an aesthetic appearance.

[0046] Second textile element 30 a is exposed by a plurality ofapertures in first textile element 20 a and adhesive element 40 a. Inmanufacturing article 10 a, an individual second textile element 30 amay be utilized to extend across all apertures, or a plurality of secondtextile elements 30 a may be associated with each of the plurality ofapertures. Similarly, an individual adhesive element 40 a may bepositioned around the plurality of apertures.

[0047] Accordingly, the specific structure of article 10 a may varysignificantly within the scope of the present invention.

[0048] An article 10 d is depicted in FIG. 15 in order to provideanother example of an application for textiles joined through the methodof the present invention. Article 10 d represents an article of apparel,such as a shirt or jersey that includes a first textile element 20 d, asecond textile element 30 d, and an adhesive element 40 d that may bejoined with a third textile element 60. The shape of the third textileelement 60 is similar to the shape of the second textile element 30 d,but slightly larger. The third textile element 60 may define an aperture62 to permit the second textile element 30 d to be visible through thethird textile element 60.

[0049] Referring to FIGS. 13 and 14, the third textile element 60 andadhesive element 40 d are positioned over the second textile element 30d and joined with the second textile element 30 d. As above with theprevious embodiment, the combination of third textile element 60 andadhesive element 40 d with the second textile element 30 d form a designin article 10 d, such as a number as depicted in FIGS. 13-15. The designformed by the combination of the third textile element 60, adhesiveelement 40 d, and second textile element 30 d may then be positionedover and joined to the first textile element 20 d, as depicted in FIG.15. The adhesive element 40 d may be used to bond the third textileelement 60 and second textile element 30 d to the first textile element20 d. Alternatively, the third textile element 60 and second textileelement 30 d may be embroidered onto the first textile element 20 d,using conventional sewing techniques. One skilled in the relevant artwill recognize that multiple shapes and designs of the articles andtextile elements are possible and that even additional textile elementsmay be layered onto the article to provide the desired aestheticappearance of the article or textile elements.

[0050] As with the previous embodiment, the article 10 d and textileelement 20 d may be utilized, for example, as a ventilated article ofapparel, such as a mesh jersey, thereby cooling the individual. Inaddition, and in contrast to known textile elements 30 d that areconventionally made of a twill fabric that does not promote ventilation,the textile element 30 d and any additional layered textile elements mayalso be a ventilated material, such as a mesh material, that provides arelatively high degree of air-permeability to cool the individual. Inother words, during exercise, air may enter and exit the area betweenarticle 10 d and the individual by passing through the first and secondtextile elements 20 d and 30 d, respectively. Moreover, the textileelements 20 d and 30 d may be formed of a material that wicks moistureaway from the skin, thereby limiting the amount of moisture on theinterior of article 10 d.

[0051] Articles 10, 10 a and 10 d provide examples of structuresproduced through the method of the present invention. The followingdiscussion will disclose the method in terms of the various componentsof article 10. One skilled in the relevant art will recognize thatconcepts disclosed with respect to the method may also be applied toarticles 10 a, 10 d, or any other article requiring textile elements tobe joined, such as articles 10 b and 10 c, which are disclosed below.

[0052] The method includes four general steps. As an initial step in themethod, first textile element 20, second textile element 30, andadhesive element 40 are produced. A first bond is then formed betweenfirst textile element 20 and adhesive element 40 to define a bonded areaand an unbonded area. Apertures 23 and 43 are then defined in firsttextile element 20 and adhesive element 40, respectively, by removing atleast a portion of the bonded area. Finally, a second bond is formedbetween second textile element 30 and the bonded area, thereby joiningfirst textile element 20 and second textile element 40. Each of thesteps will be discussed in detail in the following material.

First Step—Producing the Elements

[0053] The first step in the method is generally depicted in FIG. 6 andinvolves producing first textile element 20, second textile element 30,and adhesive element 40. In general, first textile element 20 is joinedwith other textile elements to form an article of apparel or other itemof manufacture. Accordingly, first textile element 20 should be producedto have a shape and size consistent with the particular application forwhich article 10 is being manufactured. Similarly, the material fromwhich first textile element 20 is produced should be appropriate for theparticular application. As discussed above, the material may varysignificantly within the scope of the present invention to include anytextile. Alternately, first textile element 20 may have an undefinedshape that may be cut to specific dimensions during other steps of themethod or following completion of the method. Following the method,first textile element 20 includes aperture 23. During the first step,however, aperture 23 is absent such that first textile element 20 has acontinuous configuration.

[0054] Second textile element 30 and adhesive element 40 are generallyproduced to have the same dimensions. Accordingly, second textileelement 30 and adhesive element 40 may be produced simultaneously orseparately from sheet materials through a die cutting operation, forexample. The rationale behind producing second textile element 30 andadhesive element 40 to have the same dimensions relates to the finalconfiguration of article 10, wherein, outer edge 31 and outer edge 41coincide. If adhesive element 40 were larger than second textile element30, adhesive element 40 would be visible to the individual and maypresent a non-aesthetic appearance to article 10. If adhesive element 40were smaller than second textile element 30, the polymer materialforming adhesive element 40 may not infiltrate the area adjacent toouter edge 31, thereby permitting unraveling or fraying of outer edge31. With knowledge of the limitations discussed above, however, secondtextile element 30 and adhesive element 40 may be produced to havediffering dimensions within the scope of the present invention.

[0055] The materials selected for second textile element 30 may vary toinclude any of the materials suitable for first textile element 20. Ingeneral, first textile element 20 and second textile element 30 arejoined to provide a benefit relating to a combination of the differentmaterials. For example, first textile element 20 and second textileelement 30 may have different colors or textures to provide a specificaesthetic appearance, or first textile element 20 and second textileelement 30 may be produced from different materials to enhance abrasionresistance in a specific portion of article 10. In addition, secondtextile element 30 may be produced from a mesh material that forms avent in article 10. Accordingly, the material selected for secondtextile element 30 may vary significantly within the scope of thepresent invention to provide a different property to a portion ofarticle 10.

[0056] The materials selected for adhesive element 40 may include anythermoplastic polymer, for example, as discussed above. A furtherconsideration regarding adhesive element 40 relates to the manner inwhich adhesive element 40 is bonded with first textile element 20 in thesecond step, described hereafter. In general, heat and pressure areapplied to form the bond. If adhesive element 40 were merely athermoplastic polymer material, a portion of the polymer may bond withor otherwise engage the structure that applies the heat and pressure. Inorder to alleviate this possibility, a carrier sheet may be applied toone surface of adhesive element 40. The carrier sheet may be paper, apolymer having a higher melting temperature, or any other material thatwould effectively prevent molten portions of adhesive element 40 fromengaging the structure that applies the heat and pressure.

Second Step—Forming the First Bond

[0057] The second step in the method is generally depicted in FIGS. 7and 8 and involves forming a first bond between first textile element 20and adhesive element 40. With reference to FIG. 7, first textile element20 and adhesive element 40 are depicted as being positioned adjacent toeach other and between a surface 51 and a platen 52 of a bondingapparatus. Surface 51 may be a stationary component of the bondingapparatus upon which first textile element 20 and adhesive element 40are placed. Platen 52, which is heated to an appropriate temperature,then translates toward surface 51 and compresses first textile element20 and adhesive element 40 against surface 51. The combination of theheat and pressure supplied by platen 52 elevates the temperature ofadhesive element 40 and ensures contact between first textile element 20and adhesive element 40, thereby causing a portion of adhesive element40 to infiltrate the structure of first textile element 20. Uponsubsequent cooling, a portion of adhesive element 40 solidifies aroundthe individual fibers or filaments in first textile element 20, therebyforming the first bond. FIG. 8 depicts adhesive element 40 in a bondedrelationship with first textile element 20 following the second step.

[0058] The bonding apparatus depicted in FIG. 7 is intended to provideone example of a structure suitable for forming the first bond.Alternately, surface 51 may be replaced by another heated platen, forexample. Heat supplied through conduction is not the only method forforming the first bond. Radio frequency and ultrasonic bonding may alsobe utilized to form the first bond, which may require a substantiallydifferent type of bonding apparatus.

[0059] The degree of heat utilized to melt adhesive element 40 isprimarily dependent upon the materials forming first textile element 20and adhesive element 40. As an initial consideration, the degree of heatshould not melt or otherwise damage first textile element 20 prior tothe melting of adhesive element 40, unless such melting of first textileelement 20 is intended for forming the first bond. This considerationaside, however, the degree of heat and pressure is generally related tothe specific material forming adhesive element 40. For example, atemperature of 350° Fahrenheit and a pressure of 40 pounds per squareinch that is applied for 15 seconds is generally sufficient to form thefirst bond when adhesive element 40 is a polyurethane material.Similarly, a temperature between 325 and 375° Fahrenheit and a pressurebetween 60 and 80 pounds per square inch that is applied for a timebetween 10 and 15 seconds is generally sufficient to form the first bondwhen adhesive element 40 is a vinyl or polyamide material.

Third Step—Defining the Aperture

[0060] The third step in the method is generally depicted in FIG. 9 andinvolves defining apertures 23 and 43 through first textile element 20and adhesive element 40, respectively. Apertures 23 and 43 have beendiscussed as separate apertures due to their formation through twoseparate elements. In effect, however, the step of defining apertures 23and 43 provides a single aperture that extends through both firsttextile element 20 and adhesive element 40.

[0061] A die cutting operation or any other operation suitable forremoving a portion of adhesive element 40 and a corresponding portion offirst textile element 20 may be utilized to define apertures 23 and 43.In general, apertures 23 and 43 are defined in the portion of article 10where adhesive element 40 is bonded to first textile element 20. Duringthe second step, adhesive element 40 is bonded to first textile element20, which defines a bonded area and an unbonded area. The bonded areais, therefore, the portion where first textile element 20 and adhesiveelement 40 are bonded, and the unbonded area is the portion of firsttextile element 20 that is not bonded to adhesive element 40.Accordingly, apertures 23 and 43 are defined through the bonded area.

[0062] The general purpose of adhesive element 40 is to join firsttextile element 20 and second textile element 30 around apertures 23 and43. Accordingly, apertures 23 and 43 are defined in a manner that leavesa portion of adhesive element 40 extending entirely around aperture 23.The shape of apertures 23 and 43 may be proportioned to have the sameshape as second textile element 30, but with lesser dimensions. Thisconfiguration ensures that apertures 23 and 43 fit entirely within thebonded area. The shape of apertures 23 and 43 may also be such that theremaining portion of adhesive element 40 has a uniform width betweenedges 41 and 42. Alternatively, many apertures may be defined throughfirst textile element 20 and adhesive element 40, as in article 10 a. Asanother alternative, some articles may not require apertures, as inarticle 10 d. As a result, the third step of the method is unnecessary.

[0063] Adhesive element 40 may include a carrier sheet, as discussedabove. During the third step of the method, the carrier sheet may beremoved in order to prepare adhesive element 40 for bonding with secondtextile element 30 in the fourth step of the method.

Fourth Step—Forming the Second Bond

[0064] The fourth step in the method is generally depicted in FIGS. 10and involves forming a second bond between second textile element 30 andadhesive element 40. With reference to FIG. 10, first textile element20, second textile element 30, and adhesive element 40 are depicted asbeing positioned adjacent to each other and between a surface 51′ and aplaten 52′ of a bonding apparatus, which may be the same bondingapparatus utilized during the second step. Surface 51′ may be astationary component of the bonding apparatus. Platen 52′, which isheated to an appropriate temperature, then translates toward surface 51′and compresses second textile element 30 and adhesive element 40. Thecombination of the heat and pressure supplied by platen 52′ elevates thetemperature of adhesive element 40 and ensures contact between secondtextile element 30 and adhesive element 40, thereby causing a portion ofadhesive element 40 to infiltrate the structure of second textileelement 30. Upon subsequent cooling, a portion of adhesive element 40solidifies around the individual fibers or filaments in second textileelement 30, thereby forming the first bond. FIGS. 1-4 depict firsttextile element 20, second textile element 30, and adhesive element 40following the second step.

[0065] The melting temperature of adhesive element 40 is generally thesame in the fourth step as during the second step. The same temperatureand pressure may, therefore, be applied to form the second bond.Depending upon the speed with which the third step is performed,residual heat may remain within adhesive element 40 prior to theapplication of heat and pressure in the fourth step. Accordingly, thetime period for the application of the heat and pressure may beshortened to account for the residual heat.

Further Textile Joining Configurations

[0066] With respect to article 10, aperture 23 and aperture 43 areformed on interior portions of first textile element 20 and adhesiveelement 40, respectively. That is, apertures 23 and 43 are spaced inwardfrom the outer edges of elements 20 and 40. The general method disclosedabove, however, may be applied to configurations wherein apertures areformed in edge portions of one or more of the elements. For example,FIG. 11 depicts an article 10 b that includes a first textile element 20b, a second textile element 30 b, and an adhesive element 40 b. Informing article 10 b, adhesive element 40 b is bonded to first textileelement 20 b and an aperture, which corresponds with aperture edge 22 b,is defined on an edge portion of both first textile element 20 b andadhesive element 40 b, rather than through interior portions. In otherwords, the apertures in first textile element 20 b and adhesive element40 b are not spaced from all outer edges of the elements. Adhesiveelement 40 b is then utilized to join first textile element 20 b withsecond textile element 30 b. In this configuration, therefore, textileelement 40 b extends into an interior portion of article 10 b and sharesa common outer edge with first textile element 20 b.

[0067] Referring to FIG. 12 an article 10 c having a first textileelement 20 c, a second textile element 30 c, and an adhesive element 40c is depicted. An aperture corresponding with aperture edges 22 c and 22c′ is defined through both first textile element 20 c and adhesiveelement 40 c. Whereas the aperture extends through an interior portionof first textile element 20 c, the aperture is positioned on an edgeportion of adhesive element 40 c. Accordingly, adhesive element 40 onlyextends partially around the aperture formed through first textileelement 20 c and does not extend along the portion of the aperturedefined by aperture edge 22 c′. In this configuration, adhesive element40 c joins first textile element 20 c with second textile element 30 c,but a portion of the edge of second textile element 30 c remainsunbonded to first textile element 20 c. That is, second textile element20 c remains unbonded along aperture edge 22 c′. This configuration maybe utilized, for example, to provide a pocket or access opening througharticle 10 c.

Conclusion

[0068] The general method described above may be applied to a wide rangeof products to join various textile elements. An article formed throughthe method has advantages over articles formed through conventionalsewing techniques. For example, the article may include textile elementswith any practical shape, whether the shape includes angles,small-radius curves, or other complex features. From an aestheticperspective, the ability to join elements with any practical shapeprovides the capacity to incorporate a functional graphic into thearticle. As discussed with respect to articles 10 a and 10 d, a meshmaterial may be integrated into the article that serves to ventilate thearticle and provide a specific aesthetic to the article. In addition,edges of the elements do not need to be surged, hemmed, or turned toprevent unraveling or fraying. Furthermore, the seams generally have athickness of two textile layers, rather than the three or more producedthrough conventional sewing techniques.

[0069] The present invention is disclosed above and in the accompanyingdrawings with reference to a variety of embodiments. The purpose servedby the disclosure, however, is to provide an example of the variousfeatures and concepts related to the invention, not to limit the scopeof the invention. One skilled in the relevant art will recognize thatnumerous variations and modifications may be made to the embodimentsdescribed above without departing from the scope of the presentinvention, as defined by the appended claims.

That which is claimed is:
 1. A method of joining a plurality of textileelements, the method comprising the steps of: providing a first textileelement, a second textile element, a third textile element, and anadhesive element; forming a first bond between the third textile elementand the adhesive element, forming a second bond between the secondtextile element and the adhesive element, thereby joining the thirdtextile element and the second textile element; and attaching the joinedsecond and third textile elements to the first textile element.
 2. Themethod of claim 1, wherein the step of forming the first bond includesheating the adhesive element and the third textile element.
 3. Themethod of claim 2, wherein the step of forming the first bond includesapplying pressure to the adhesive element and the third textile element.4. The method of claim 2, wherein the step of forming the first bondincludes applying pressure with a platen of a heated press.
 5. Themethod of claim 1, wherein the step of forming the first bond includeslocating the first bond in a spaced relationship with all outer edges ofthe second textile element.
 6. The method of claim 1, wherein the stepof forming the first bond includes locating the first bond in a spacedrelationship with at least some outer edges of the second textileelement.
 7. The method of claim 1, wherein the step of providing a thirdtextile element includes forming an aperture within the third textileelement.
 8. The method of claim 1, wherein the step of attaching thejoined second and third textile elements to the first textile elementincludes bonding the joined second and third textile elements to thefirst textile element.
 9. The method of claim 1, wherein the step ofattaching the joined second and third textile elements to the firsttextile element includes sewing the joined second and third textileelements to the first textile element.
 10. The method of claim 1,wherein the step of forming the second bond includes heating theadhesive element and the second textile element.
 11. The method of claim10, wherein the step of forming the second bond includes applyingpressure to the adhesive element and the second textile element.
 12. Themethod of claim 11, wherein the step of forming the second bond includesapplying pressure with a platen of a heated press.
 13. The method ofclaim 1, further including a step of shaping the second textile element,and third textile element, and the adhesive element to havesubstantially similar dimensions.
 14. The method of claim 1, furtherincluding a step of selecting the adhesive element to include athermoplastic polymer material.
 15. The method of claim 1, wherein thestep of providing a first and second textile element includes using amesh material.
 16. A method of joining a plurality of textile elements,the method comprising the steps of: providing a first textile element, asecond textile element, and an adhesive element; forming a first bondbetween the second textile element and the adhesive element through theapplication of heat and pressure, forming a second bond between thefirst textile element and the adhesive element through the applicationof heat and pressure, thereby joining the second textile element and thefirst textile element; and attaching the joined first and second textileelements to an article of clothing.
 17. The method of claim 16, whereinthe step of providing an adhesive element includes selecting theadhesive element to include one of a group consisting of polyamide,polyester, polyolefin, and vinyl.
 18. The method of claim 16, whereinthe step of providing an adhesive element includes selecting theadhesive element to include a polyurethane material.
 19. The method ofclaim 16, wherein the steps of forming the first and second bondsinclude applying the heat and the pressure with a platen of a press. 20.The method of claim 16, wherein the step of providing a first and secondtextile element includes using a mesh material for one of the first orsecond textile elements.
 21. The method of claim 16, further including astep of shaping the first textile element, the second textile element,and the adhesive element to have substantially similar dimensions. 22.The method of claim 16, wherein the step of attaching the joined firstand second textile elements to the article of clothing includes bondingthe joined first and second textile elements to the article of clothing.23. The method of claim 16, wherein the step of attaching the joinedfirst and second textile elements to the article of clothing includessewing the joined first and second textile elements to the article ofclothing.
 24. An article comprising: a first textile element; a secondtextile element extending over the first textile element and connectedto the first textile element; and a third textile element extending overthe second textile element and bonded to the second textile elementthrough the use of an adhesive element.
 25. The article of claim 24,wherein the bonded second and third textile elements are bonded to thefirst textile element.
 26. The article of claim 24, wherein the bondedsecond and third textile elements are sewn to the first textile element.27. The article of claim 24, wherein the adhesive element includes athermoplastic polymer material.
 28. The article of claim 24, wherein theadhesive material includes a polyurethane material.
 29. The article ofclaim 24, wherein the article is incorporated into an article ofapparel.
 30. The article of claim 24, wherein the first and secondtextile elements are made of a mesh material.
 31. The article of claim24, wherein the second textile element is made of a mesh material toform a vent in the article.
 32. The article of claim 31, wherein thesecond textile element is shaped to form a functional design.
 33. Thearticle of claim 24, wherein the second and third textile elements, andthe adhesive element each define an outer perimeter, wherein theperimeters of the second and third textile elements, and the adhesiveelement, have proportional dimensions.
 34. An article comprising: afirst textile element; a second textile element extending over the firsttextile element; and a third textile element extending over the secondtextile element and bonded to the second textile element through the useof an adhesive element, the bonded second and third textile elements aresewn to the first textile element.
 35. The article of claim 34, whereinthe adhesive element includes a thermoplastic polymer material.
 36. Thearticle of claim 34, wherein the adhesive material includes apolyurethane material.
 37. The article of claim 34, wherein the articleis incorporated into an article of apparel.
 38. The article of claim 34,wherein the first and second textile elements are made of a meshmaterial.
 39. The article of claim 34, wherein the second textileelement is made of a mesh material to form a vent in the article. 40.The article of claim 39, wherein the second textile element is shaped toform a functional design.
 41. The article of claim 40, wherein an outeredge of the second textile element and an outer perimeter of theadhesive element have substantially similar dimensions.
 42. The articleof claim 34, wherein the second and third textile elements, and theadhesive element each define an outer perimeter, wherein the perimetersof the second and third textile elements, and the adhesive element, haveproportional dimensions.